Loop pile fabric



Feb. 26, 1963 G. BLOCH LOOP 'PILE FABRIC Filed July 1 1, 1960 INVENTOR GODFREY BLOCH AT T0 R N EY 3,078,543 LOOP PILE FABREC Godfrey Bloch, 38 E. 75th St., New York, NY. Filed Euly 14, 1969, Ser. No. 42,893 4 Claims. (Cl. 28-78) This invention relates to loop pile fabric and has for an object to provide a fabric of the above type having novel and improved characteristics.

Another object is to provide a loop pile fabric wherein the pile yarns are composed of a blend of wool fibers and staple length fibers of a synthetic material having a high degree of hardness, tensile strength and wear resistance.

Another object is to provide a fabric of the above type wherein fuzziness and pilling is largely avoided.

Other objects and advantages will be apparent as the nature of the invention is more fully disclosed.

In a loop pile fabric wherein the pile yarns are composed of spun wool any loose wool fiber ends which may appear are broken off and removed in ordinary vacuum cleaning, thereby preventing the formation of a fuzzy or napped appearance. However, in the case of spun nylon or polypropylene fibers there is less tendency for the loose ends to be broken off because of their high tensile strength. Hence the ends remain to produce a fuzzy or napped effect and due to their length may roll into balls or pills which produce an uneven surface appearance.

Synthetic fibers of the above type are desirable however because of their hardness and wear resistance.

In accordance with the present invention the desirable properties of both wool and the above mentioned synthetic fibers are utilized to obtain a novel and improved effect.

This is accomplished by spinning the pile yarns from a fiber blend composed of wool fibers and synthetic fibers of nylon or polypropylene wherein the synthetic fibers are of two different deniers.

It has been found for example that a blend containing synthetic fibers of fifteen denier in amounts up to ten to twenty percent, when hard twisted and set, does not pill to an undesirable extent. On the other hand synthetic fibers of smaller denier such as six denier have less tensile strength and can be broken off in a manner similar to wool fibers in the usual vacuuming process. Yet these fibers impart hardness and wear resistance to the fabric.

Thus a blend composed of 76% to 80% wool fibers, to 12% nylon fibers or polypropylene fibers of staple length and of about fifteen denier, and 10% to 12% of the same synthetic fiber having a denier of about six can be used without objectionable pilling or fuzzing. This yarn has the bulk and resilience of a wool yarn and the stiffness and wear resistance of a yarn composed essentially of the above mentioned synthetic materials.

As an example, 78% wool is blended with 11% of fifteen denier nylon and 11% of six denier nylon. The blend is spun into a single yarn about 2000 yards per pound with a twist of five turns per inch. It is then plied 2-ply in reverse twist about six and one-half turns per inch. Pairs of loops are Woven each pair being one regular and one reverse twist in a plain staggered weave, twelve pile yarns per inch, twelve ground cotton yarns of 6S 4-ply cotton count and 10 picks of sixteen pound jute.

After weaving the fabric is latexed on the back and dried. After it is dried, hot air is applied to the face to heat-set the nylon in the yarns. This is done while heat 3,078,543 Patented Feb. 26, 1953 is still being applied to the back to complete the cure.

A loop pile fabric of carpet type is illustrated in the drawing wherein the FIGURE is a warpwise section of such fabric.

Referring to the drawing more in detail, the invention is shown as embodied in a pile carpet fabric having a woven backing composed of filler yarns iii and chain yarns ll of the usual heavy backing yarn material such as ute.

The pile is shown as composed of pile loops 12, each loop being formed by a pair of yarns l3 and 14. In Weaving the fabric of the pile yarns l3 and 14 may be fed through the same reed dent, or through the same heddle eye, or in the case of a tufted fabric may be fed through the same heddle eye so that the two yarns lie in close contact in the pile loops and in the backing.

The pile fabric may be woven on a stationary wire loom mechanism wherein the pile loops are laid over the stationary wires first in one direction and then in the other in successive rows. This Weave causes the two yarns to lie in close contact at various points.

The yarns 13 and 14 are spun yarns composed of a blend of wool and synthetic fibers as above described, the two yarn-s being preferably twisted in opposite directions so as to improve the overall appearance.

In a loop pile fabric of the above type it has been found that the loops have the resilience and fluifiness inherent in wool and that the fifteen denier nylon or polypropylene would impart hardness, stiffness and wear resistance without being present in an amount such that objectionable loose ends are formed. The six denier nylon or polypropylene increases the hardness and wear resistance of the fabric and at the same time does not produce objectionable fuzziness or pilling since this material breaks off when loose ends appear.

The invention is applicable to loop pile fabrics made by weaving, knitting or t-ufting.

A specific embodiment has been illustrated for convenience only.

What is claimed is:

1. A loop pile fabric comprising a backing and pile loops anchored therein, said pile loops comprising a spun yarn composed of a blend of wool fibers and synthetic fibers of staple length, said synthetic fibers having a high tensile strength and surface hardness, the synthetic fibers of the blend being selected from the group consisting of nylon and polypropylene and being of at least two different deniers in about equal proportions, one of said deniers being of a fineness such that loose ends tend to be broken off in cleaning and removed, the other of said deniers being of a size such as to resist the breaking off of loose ends in cleaning to provide stiffness and tensile strength to the blend.

2. A loop pile fabric as set forth in claim 1 wherein said wool fibers comprise about 76% to 80% of the blend and the synthetic fibers comprise about 24% to 20% of the blend.

3. A loop pile fabric as set forth in claim 1 wherein said yarn is hard twisted and heat set in hard twisted state.

4. A loop pile fabric as set forth in claim 1 in which said synthetic fibers have deniers of the Order of six and fifteen respectively.

References Cited in the file of this patent UNITED STATES PATENTS 

1. A LOOP PILE FABRIC COMPRISING A BACKING AND PILE LOOPS ANCHORED THEREIN SAID PILE LOOPS COMPRISING A SPUN YARN COMPOSEN OF A BLEND OF WOOL FIBERS AND SYNTHETIC FIBERS OF STAPLE LENGTH, SAID SYNTHETIC HAVING A HIGH 